Integrated Planning for Precision Machining of Complex Surfaces

9500020 Menq本研究的目标是为复杂表面几何形状的精密加工开发一个集成框架，其中产品质量和生产率在工艺开发阶段而不是在生产周期的制造阶段进行计划和控制。立铣削是三维曲面加工中应用最广泛的加工工艺之一。建立可靠的数学过程模型来确定立铣削的最佳加工条件。第一个任务将是开发预测模型的切削力和由此产生的表面误差在各种端铣削过程。第二项任务是开发先进的加工策略和补偿方案，利用已开发的预测能力来规划最佳的切削路径和进给速度，以减少生产时间和成本，并在实际加工表面之前通过纠正预期误差来提高产品质量。在美国大约有5万家小型机械工厂可以从这项研究中获得一些好处。本研究旨在提高对铣削过程中切削性能和尺寸误差形成的理解，并为复杂几何表面的精密加工开发一个集成框架。所建立的模型可以在开放的计算机辅助设计与制造系统中实现，从而建立三维雕刻曲面加工的智能加工规划系统。

9500020 Menq The goal of this research is to develop an integrated framework for precision machining of complex surface geometries, in which product quality and productivity are planned and controlled in the process development phase rather than in the manufacturing phase of the production cycle. The present study focuses on end milling, one of the most widely used machining processes in the manufacture of parts with three-dimensional sculpted surfaces. Reliable mathematical process models will be developed to determine the optimum machining conditions in end milling. The first task will be to develop predictive models for cutting forces and the resulting surface errors in various end milling processes. The second task is to develop advanced machining strategies and compensation schemes that utilize the developed predictive capability to plan optimal cutting paths and feedrates for the reduction of production time and costs, and to improve product quality by correcting the anticipated errors before actually machining a surface. There are about fifty thousand small machine shops in the United States that could gain some benefit from this research. The research is intended to enhance the understanding of the cutting performance and dimensional error formation in the end milling process, and to develop an integrated framework for precision machining of complex surface geometries. The models developed here can be implemented in an open computer-aided design and manufacturing system to establish an intelligent machining planning system for three-dimensional sculptured surface machining.